Method and means for constructing masonry walls

ABSTRACT

A spacer/centering element includes on its periphery and/or close thereto, feet as zonal resting intermediaries for blocks pertaining to two superposed rows and, on one side thereof, first centering devices for engaging a hole in a block and, on the opposite side thereof, second centering offset from the first and arranged to engage a hole in an overlying block devices.

The present invention relates to a method and means for constructingmasonry walls of prefabricated cementitious blocks.

The method currently used to construct masonry walls of cementitiousblocks is based essentially on exhausting slow manual work. In thisrespect, on examining this method in detail it will be noted that the(qualified) bricklayer applies to the upper face of a horizontalsuccession of blocks relatively thick runs of mortar along two sides ofthe blocks, which have already received a layer of mortar applied to oneof their lateral faces to obtain a lateral bond between one block andthe next. The bricklayer places on the resultant row of blocks a row ofblocks offset from the underlying row, this operation involving:

-   I. careful horizontal and vertical positioning of the individual    blocks, and-   II. falling of the excess mortar, which not only soils the wall    under erection but also constitutes an irrecoverable wastage, which    is disposed of.

The main object of the present invention is to provide a method andmeans which represent an innovation compared with the aforedescribedmethod and enable:

-   A. a definite acceleration in the construction of the masonry wall;-   B. a simplification of this construction such that it can be carried    out by unqualified personnel;-   C. a considerable saving in mortar consequent on the practical    reduction in wastage;-   D. complete verticality of the masonry wall obtained.

These and further objects of the present invention are attained by themethod and means in accordance with the accompanying claims.

The invention will be more apparent from the ensuing detaileddescription of preferred embodiments thereof provided by way ofnon-limiting example with reference to the accompanying drawings, inwhich:

FIG. 1 is a perspective view of a spacer/centering elementrepresentative of the essence of the invention, the view showing oneside of said spacer/centering element;

FIG. 2 is a perspective view of the spacer/centering element taken onthe opposite side;

FIG. 3 is a schematic side view of three cementitious blocks partiallyshown by dashed lines, with an interposed spacer/centering element priorto injection of the consolidating mortar;

FIG. 4 is a perspective view of a number of blocks arranged with thespacer/centering elements located on the holes of these blocks;

FIG. 5 is a perspective view from above of a partially reproduced block,the view showing the position of the underlying spacer/centering elementin situ;

FIG. 6 is a schematic view showing the finishing operation by injectingmortar into the interspaces between blocks using an injection machineschematically reproduced.

With reference to the figures, the cementitious blocks 1 with which awall is to be erected are widely known and standardized; they aresimilar in shape to a right (rectangular) parallelepiped having twoparallel through holes 2, 3 for lightening purposes separated by anintermediate internal wall 4. The holes are conical or tapered.

A row of blocks 1 with their minor faces side by side is laid on apredisposed cementitious bed or similar cementitious surface. This rowof blocks forms the base from which the wall is erected by superposingrows of mutually offset blocks.

A spacer/centering element D (described in detail hereinafter) ispositioned on the base blocks, i.e. the blocks of the lower row, incorrespondence with the openings of each of their holes 2, 3. Thisspacer/centering element D, of annular shape (moulded in plasticmaterial, for example filled polypropylene made fireproof) comprises,preferably peripherally and/or in proximity to the periphery, supportfeet 5 for example of cylindrical or pin shape, which rest along thecontour of these openings, these latter having rectilinear sidesconnected together by arcuate corners (see FIG. 5). The spacer/centeringelement D also presents (in this example) on one side (FIG. 1) a firstperipheral skirt 6 which follows the contour of the hole in the blockand enters the hole itself (via said opening). In this manner thespacer/centering element D rests on and is centered about the underlyingblock.

On the row of base blocks arranged with the spacer/centering elements,without applying mortar the operator lays in an offset arrangement asecond row of blocks, into the lower hole openings of which there isinserted a second skirt similar to the first but having a smallercontour substantially offset from said first skirt 6 by about the sameamount as the blocks of the second row are offset from the underlyingblocks.

This achieves verticalized centering of said second row of blocks. Theblocks of this second row rest on the top of said peripheral feet 5 ofthe spacer/centering elements D. It is apparent that each of these feetacts as a support and spacer between one row and another of the blocks,to hence obtain the horizontal interspaces A between one row of blocksand the next.

When this second row of blocks has been superposed dry, i.e. withoutmortar, the spacer/centering elements D are placed in position (asalready stated) in the upper openings of the holes 2, 3 of the secondrow of blocks, a third row of blocks then being located in theaforestated manner, then proceeding from row to row in the stated manneruntil a certain wall height is achieved, this height being related to orlimited by the strength of those support feet 7 most loaded by theoverlying weight. After this, mortar is injected into both thehorizontal and vertical interspaces.

For the injection, a nozzle 8 is provided having a wide and narrow exitmouth 9 (similar to the interspaces) and fed with mortar from a vessel10 by means of a screw feeder 13; the feed can be controlled by a valve(not shown). To the side of the nozzle 8 there is provided a profiledsmoother bar 11 with which the external face of the injected mortarlayer is finished. As can be seen from the figures showing thespacer/centering element D, the skirts 6, 7 of the spacer/centeringelement D comprise rounded corner portions 6 a, 7 a with a taperedlead-in end to provide effective centering, and intermediate parts 6 b,7 b of undulated shape. With their depressions and the facingsurrounding surface of the hole in the block, the undulations formchannels 13 (FIG. 6) through which the mortar also reaches the sides ofthese holes, to give rise to the formation of inward projections whenthe mortar has set.

The injected mortar solidifies to replace the support feet 5 for thestatic support of the wall.

When one wall height has been finished, the wall erection can becontinued until completion by proceeding in the aforedescribed manner.Finally it should be noted that in order to enable the blocks to beremoved from their production moulds, their holes 2, 3 narrow from oneend to the other. To take account of this the skirts 6 and 7 are ofdifferent perimeters but of substantially equal design (as can be seenespecially from FIGS. 1, 2).

In a variant of the invention the undulations can be dispensed with, thecentering function being entrusted to only the corner portions 6 a, 6 b.The spacer/centering element D defines an aperture A to enable possiblepassage of reinforcing rods for constructing pillars obtainable, as inthe known art, by casting cementitious mortar into the holes 2, 3 of theblocks, which are virtually superposed in the erected wall.

1. A method for constructing a wall with prefabricated cementitiousblocks in the form substantially of a right prism and provided withthrough lightening holes, which extend vertically in the constructedwall, in which the blocks are arranged offset from row to row,characterised by zonally resting, on the contour of the openings in thethrough holes of the blocks of one row, spacer/centering elementsprovided with first parts engaging in said holes for the purpose ofcentering said elements, on said one row there being superposed a secondrow of blocks to zonally rest on said spacer/centering elements, whichare provided with second parts engaging in the holes of said second rowfor the purpose of centering the blocks of the second row, saidoperations involving said spacer/centering elements being repeated untilat least a part of the wall has been erected, in the wall or its thuserected part there appearing interspaces (F) between the rows of blocks,which are sealed by injecting mortar thereinto.
 2. A spacer/centeringelement for implementing the method claimed in the preceding claim,characterised by comprising, preferably on its periphery and/or closethereto, feet (5) as zonal resting intermediaries for blocks (1)pertaining to two superposed rows and, on one side thereof, firstcentering means (6 a), for engaging a hole (2, 3) in a block (1) and, onthe opposite side thereof, second centering means (7 a) offset from thefirst and arranged to engage a hole in an overlying block.
 3. Aspacer/centering element as claimed in claim 2, wherein the first andsecond centering means (6 a, 6 b) are skirts (6, 7) or parts thereofshaped in accordance with at least part of the profile of the hole (2,3) of the block (1) in which they are to engage.
 4. A spacer/centeringelement as claimed in claim 3, wherein the feet (5) are pin shaped andare at least partly disposed along the outer contour of said element. 5.A spacer/centering element as claimed in claim 1, wherein the skirts (6,7) comprise undulating intermediate parts or portions (6 b, 7 b) toenable injected mortar to also pass into the interior of the holes (2,3) in the blocks when the spacer/centering element has been mounted. 6.A spacer/centering element as claimed in claim 1, characterised bybounding a central aperture.
 7. A spacer/centering element as claimed inclaim 1, characterised by being moulded of fireproof plastic material.